The is my first attempt at a bike generator and I have made many improvements to section 14.3 mechanical advantage and efficiency answers pdf project. 2 AA batteries and powers the lights. I made this friction drive bike generator to power my head light and tail light.

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I recently bought a bike to commute to work and around town and figured for safety’s sake I’d get a light set. There are many instructables on bike lights too. I got this bike for its simplicity, single speed means I can just hop on and go, but replacing batteries gets expensive and complicates things to much. By adding the generator I can power the lights while riding. Thanks to instrutables member aaronscottaugustinhotmail. Your going to need a few things if you want to build a bike generator. 1x Bike Reflector bracket – I took this off my bike when I put the lights on.

Small rubber wheel – This attaches to the stepper motor and rubs against the wheel as it spins. Now lets make the circuit. Its a good idea to test everything before you start soldering it all together, so I built the whole circuit on the solderless bread board first. I started with the motor connector and the diodes. I desoldered the connector from the circuit board of the printer.

The stepper motor has two coils in it and you need to make sure each coil is wired to one set of the diode groups. To find out which wires from the motor are connected to the same coil you just need to check for continuity between the leads. Two of the wires are connected to the first coil and two of them are connected to the second coil. Once the circuit was built on the solderless bread board I tested it. The motor produced up to 30 volts while riding the bike normally.

It is a 24volt stepper so this seems reasonable. With the voltage regulator installed the output was a constant 3. The resistors control the output voltage and the 150 and 220 Ohm resistors were chosen to get 3. Now it just need soldered to the PC board. I used small gage solder to make all the connections. It heats up faster and allows for better connections that only bridge where you want them to. The curved lines are the wires shown in some of the pictures and the short black straight lines are were you need to make the solder bridges.

2″ aluminum angle and the reflector bracket. Holes were drilled in the aluminum to mount the motor first. Then one side of the angle was cut out to make room for the wheel. The wheel was attached by wrapping electrical tape around the motor’s shaft until there was enough to allow the wheel to be forced over the tape. This method works for now but will probably need upgraded in the future.

Once the motor and wheel were attached to the aluminum I found a suitable place on the frame to mount everything. I mounted mine to the seat tube. My bike is a 61cm frame so the area where the generator is mounted is fairly large compared to smaller frame bikes. Just find the best location on your bike to mount the generator.

After I found a good location I marked the aluminum bracket, with the reflector bracket in place, so that it could be cut to size. Then drilled holes in the bracket and the aluminum and mounted the whole thing to the bike. Now all thats needed is to hook it up to the head light. The wires were then connected to the battery connector. I used this because I wanted to be able to disconnect the the head light quickly. The project box will need slots or holes for the wires for the light and the motor.

Once everything is on go out and ride! What is this generating and for what purpose please? Very interesting intractable, why did you choose a stepper instead of a straight DC brushless? I do, is there any circuitry protects against rolling backwards and outputting the reverse polarity from the motor?